Plastic brush guide

Abstract

The present invention in one embodiment is an engine cooling fan module including a motor having a horizontally extending motor shaft, at least one plastic brush guide defining a guide axis aligned with the motor shaft, the at least one plastic brush guide including a first side wall portion extending along the guide axis, a second side wall portion generally opposite the first side wall portion, and a top portion extending between the first side wall portion and the second side wall portion, the second side wall portion defining a radial slot opened at an inner portion of the plastic brush guide, a brush slidingly positioned within the plastic brush guide, and a shunt electrically coupled to the brush and extending through the radial slot.

The invention claimed is: 
     
       1. An engine cooling fan module comprising:
 a motor having a horizontally extending motor shaft; 
 at least one plastic brush guide defining a guide axis aligned with the motor shaft, 
 the at least one plastic brush guide including a first side wall portion extending along the guide axis, a second side wall portion generally opposite the first side wall portion, and a top portion extending between the first side wall portion and the second side wall portion, the second side wall portion defining a radial slot opened at a radially inward end of the second side wall; 
 a brush slidingly positioned within the plastic brush guide; and 
 a shunt electrically coupled to the brush and extending through the radial slot. 
 
     
     
       2. The engine cooling fan module of  claim 1 , wherein the at least one plastic brush guide comprises:
 a base portion supporting the first side wall; 
 a first support track extending along the guide axis; and 
 a first ventilation channel extending along the guide axis and defined in part by the first support track, such that the brush is slidingly positioned on the first support track and the first ventilation channel is directly beneath the brush, 
 wherein no radially extending slot is defined on the first sidewall. 
 
     
     
       3. The engine cooling fan module of  claim 2 , further comprising:
 a second ventilation channel extending along the guide axis directly above the brush, 
 wherein the at least one plastic brush guide further includes at least three stanchions configured to support the at least one plastic brush guide. 
 
     
     
       4. The engine cooling fan module of  claim 3 , further comprising:
 at least one ventilation port in fluid communication with the second ventilation channel and extending through the top portion. 
 
     
     
       5. The engine cooling fan module of  claim 1 , wherein the at least one plastic brush guide is part of a brush plate, the engine cooling fan module further comprising:
 a spring slot formed in the brush plate; and 
 a spring including a biasing portion positioned in the at least one plastic brush guide and a shoulder extending laterally away from the at least one plastic brush guide, at least a portion of the shoulder positioned within the spring slot. 
 
     
     
       6. The engine cooling fan module of  claim 5 , wherein:
 the brush plate further comprises a post adjacent to the at least one plastic brush guide; 
 the spring further includes (i) a shank portion extending from the shoulder in an outwardly direction away from the motor shaft, and (ii) a tail portion extending laterally away from the shank portion; and 
 at least one of the shank portion and the tail portion is wedged against the post. 
 
     
     
       7. The engine cooling fan module of  claim 6 , wherein:
 the post comprises a tail limiter; and 
 the spring is configured such that the tail portion is positioned adjacent to the tail limiter. 
 
     
     
       8. The engine cooling fan module of  claim 5 , the first side wall portion comprising:
 a lower ramp extending upwardly and laterally away from the brush to a middle portion of the side wall; and 
 an upper ramp extending downwardly and laterally away from the brush to the middle portion of the side wall, wherein the biasing portion is configured to extend along the middle portion as the brush slidingly moves within the at least one plastic brush guide. 
 
     
     
       9. The engine cooling fan module of  claim 8 , wherein the second side wall portion comprises:
 an upper portion supported by the top portion, the upper portion including a guide surface adjacent to the brush and a stepped portion spaced apart from the brush; and 
 a lower portion defining a lower side of the radial slot, the lower portion including a guide surface adjacent to the brush and a stepped portion spaced apart from the brush. 
 
     
     
       10. The engine cooling fan module of  claim 8 , wherein the top portion comprises:
 a main portion defining a lower guide surface directly above a portion of the brush; and 
 a stiffening member on an upper surface of the main portion, the stiffening member extending laterally across the main portion. 
 
     
     
       11. An engine cooling fan module comprising:
 a horizontally extending motor shaft; 
 at least one brush guide including a first side wall portion supported by a top portion of the at least one brush guide; 
 a brush slidingly positioned within the brush guide; and 
 a shunt electrically coupled to the brush and extending through a radially oriented slot located beneath the first side wall portion, wherein the radially oriented slot is opened at a radially inward end of the first side wall, wherein the first side wall portion is plastic. 
 
     
     
       12. The engine cooling fan module of  claim 11 , wherein the at least one brush guide comprises:
 a base portion; 
 a first support track extending radially outwardly from a location proximate the motor shaft; and 
 a first ventilation channel extending radially outwardly from a location proximate the motor shaft, such that the brush is slidingly positioned on the first support track and the first ventilation channel is directly beneath the brush. 
 
     
     
       13. The engine cooling fan module of  claim 12 , further comprising:
 a second ventilation channel extending radially outwardly from a location proximate the motor shaft and directly above the brush. 
 
     
     
       14. The engine cooling fan module of  claim 13 , further comprising:
 at least one ventilation port in fluid communication with the second ventilation channel and extending through the top portion. 
 
     
     
       15. The engine cooling fan module of  claim 11 , wherein the at least one brush guide is part of a brush plate, the engine cooling fan module further comprising:
 a spring slot formed in the brush plate; and 
 a spring including a biasing portion positioned in the at least one brush guide and a shoulder extending laterally outwardly from the at least one brush guide, at least a portion of the shoulder positioned within the spring slot. 
 
     
     
       16. The engine cooling fan module of  claim 15 , wherein:
 the brush plate further comprises a post adjacent to the at least one brush guide; and 
 the spring further includes (i) a shank portion extending from the shoulder in a radially outwardly direction, and (ii) a tail portion extending laterally outwardly from the shank portion. 
 
     
     
       17. The engine cooling fan module of  claim 16 , wherein:
 the post comprises a tail limiter extending laterally inwardly; and 
 the spring is configured such that the tail portion is positioned adjacent to the tail limiter. 
 
     
     
       18. The engine cooling fan module of  claim 15 , the at least one brush guide further comprising:
 a lower ramp extending upwardly and laterally outwardly to a middle portion of a second side wall located opposite to the first side wall portion; and 
 an upper ramp extending downwardly and laterally outwardly to the middle portion of the second side wall, wherein the biasing portion is configured to extend along the middle portion as the brush slidingly moves within the brush guide. 
 
     
     
       19. The engine cooling fan module of  claim 18 , wherein the first side wall portion comprises:
 an upper guide surface adjacent to the brush and a stepped portion positioned laterally outwardly from the upper guide surface. 
 
     
     
       20. The engine cooling fan module of  claim 19 , further comprising:
 a lip positioned beneath the first side wall portion, the lip and the first side wall portion defining the radially oriented slot there between.